CA1324537C

CA1324537C - Method and apparatus for improving fluid flow and gas mixing in boilers

Info

Publication number: CA1324537C
Application number: CA000616260A
Authority: CA
Inventors: Brian Robin Blackwell; Colin Maccallum
Original assignee: Sandwell Inc
Current assignee: Boiler Island Air Systems Inc
Priority date: 1988-04-15
Filing date: 1991-12-13
Publication date: 1993-11-23
Anticipated expiration: 2008-04-15
Also published as: CA1308964C; US5121700A

Abstract

METHOD AND APPARATUS FOR IMPROVING
FLUID FLOW AND GAS MIXING IN BOILERS

ABSTRACT OF THE DISCLOSURE

This invention is directed to a method and apparatus for improving fluid flow and gas mixing in boilers. More particularly, this invention pertains to a method and apparatus for improved fluid flow and gas mixing in kraft recovery boilers for increased energy efficiency, reduced TRS
emissions and increased capacity. The method of introducing air into a boiler furnace comprises: (a) introducing air through at least one opening located on at least a first wall of the interior of the furnace; and (b) introducing air through at least one second opening located on a second wall of the interior of the furnace and opposed to the first wall at the same, or different, elevations. The method of introducing air into a boiler furnace may also comprise: (a) introducing air into the furnace in the form of a first set of small and large jets originating from one wall of the interior of the furnace; and (b) introducing air into the furnace in the form of a second set of small and large jets originating from the wall of the interior of the furnace opposite the first wall. The locations of the sources of the first set of small and large jets may be placed so that they oppose the sources of the second set of small and large jets, with small jets opposing large jets, and vice versa. The sizes of the jets may be regulated by varying opening size, number of openings in groups of openings, air pressure upstream of the openings, or combinations thereof.

Description

3%4537 ~
; METHOD AND APPARATUS FOR IMPROVING
FL~ID FLOW AND GAS MIXING IN BOILERS
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FIELD OF THE INVENTION
`:' This invention is ~irected to a method and apparat-us for improving fluid flow and gas mixing in boilers. More particularly, this invention pertains to 1 l;a method and apparatus for improved fluid flow and gas .3 mixing in kraft recovery boilers for increased energy 10 eEficiency, decreased odorous TRS emissions and increased capacity to burn liquor from the pulping process.
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. BACKGRO~ND OF THE INVENTION

Boilers are widely used to generate steam for numerous applications. In the pulp and paper indus-; tries, recovery boilers are used to burn the liquor produced in a kraft pulp making process. Such boilers 20 require combustion air. The current practice for intro-, ducing combustion air into the kraft recovery boilers 91 involves injection of the air at two or more elevations 3 in the furnace of the boiler. At each of these eleva-t tions, air is injected through ports in all four walls 25 or in two opposite walls of the furnace. The port open-ings which form the air jets are usually rectangular.
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Conventional boiler systems have at least three basic deficiencies:

In some cases, the jet port openings are so ;l small that when upflowing combustion gases in the fur-nace come from below the openings, an individual jet j stream coming from a port does not have enough momentum .4 ~ .
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The combustion air is usually injected in such a way that the jet streams of combustion air interfere with each other, and the interference causes upward deflection of the jet streams. Two locations where such ~'~nterference can occur are at the centre of the furnace, where the jet streams from opposite walls of the furnace may meet head on, if they penetrate before being deflected upwards; and in the corners of the furnace, ~ where the jet streams meet at right angles and interfere j with one another.
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~ 15 When jet streams meet head on and are directed ;' upwards, they tend to be repelled somewhat such that there is an isolated space between their paths, and ` hence there is restricted mixing in these spaces.
:,1 ~3 20 Due to the lack of momentum of the jet . I , . .
streams and because of the interference between the jet streams, as described, gas in the centre of the furnace is directed sharply upwards with somewhat of a diverging - pattern. The result is a central updraft core of high ~-~` 25 gas velocity relative to the average upward gas veloc~ty at any one horizontal cross-section of the furnace.
This centraI updraft coee begins at the primary air !~ level. The updraft core has associated with it a recir-culating downflow by the furnace walls, which adds to ~i 30 the upward velocity of the gas in the centre of the fur-;l nace. It has been found that air jets located more than one to two metres above the primary air level have great difficulty penetrating this central updraft core. The chemical composition in this updraft core is unsuitable .~, ., ~ 2 -.~
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;i The primary jets, located at the lowest eleva-i tion in the furnace, are the main factor in initiating the recirculating pattern and the adverse central up-Z draft. In essentially all current recovery boiler design 3, the primary air is introduced more or less equally through multiple openings in all four walls thereby forming a plane jet stream off each wall. These four plane jet streams meet in the central region of the ; furnace and rise together. AS the jet streams issue 3 from the ports, they entrain surrounding gases. Since ~3 15 the upflow of volatiles from the char bed of the furnace is limited in volume, gases are necessarily drawn down i -- the furnace walls in order to continually replace the gases that are entrained into the upwardly flowing iet streams. This action sets up a recirculating flow 20 pattern in the furnace.

In boilers which have only one air entry level below the liquor spray level, such as older Combustion Z Engineering-type (CE-type) boilers, the central updraft 25 core has been found to occupy approximately 1/9 of the horizontal cross-sectional area in the lower furnace.
at This core extends up through the elevation where the ~3 liquor spray is introduced. The top of the recircu-X lating pattern occurs some height above the liquor spray ~l 30 level in the boiler, at an elevation corresponding , approximately to the uppermost level of air injection in such boilers - designated the tertiary air level for the purposes of this discussion. The air jets introduced at iZ this upper air level have been found to have little ~i~ 35 influence on the recirculating pattern.

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Most boilers with two levels of air entry below the liquor sprayers, such as older Babcock &
. Wilcox-type ~B&W-type) boilers and the newer CE-type bollers, have primary and secondary air ports on all four walls, with the air at a given air level being introduced more or less equally on each wall. The introductio~ of secondary air more or less equally from `~ ~,~11 four walls in such boilers reinforces the detri-mental central updraft core phenomenon.
`~ 10 `~ One of the major operational problems in kraft recovery boilers is the formation of fireside deposits -~ on the pendent heat transfer surfaces in the upper part of the boiler. The most troublesome deposits occur in the superheater and the first part of the boiler bank.
These deposits are formed mainly by particles that orig~
-. inate from the gas entrainment of some of the liquor spray particles. The mass of a particle that can be en-trained in a gas varies with about the sixth pow~r of ., 20 gas velocity. Therefore, from a conceptual perspective, it is important to minimize gas velocity extremes. AS
the liquor spray particles fall towards the bottom of the furnace, they swell and lose weight, becoming less dense, and therefore become easier to entrain. There-~3 25 fore, the most sensitive aeea for entrainment is at the char bed/primary air entry level of the furnace. A
second critical area is where there is a secondary level ~ of air entry just above the char bed. Most of the part-.' icles that are entrained upwards into the region above 30 the liquor spray level by the upwardly flowing gases 3 are essentially destined to be carried out of the furnace by the furnace exit gas. Therefore, for the air ~ introduced above the liquor spray level, gas velocity is i~ not as much of a concern relative to minimizing fireside .1 ~ 35 deposition.

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- ' ~L32~37( U.S. Patent No. 2,416~462 Wilcoxson~ discloses a concept involving an interlacing pattern of unopposed jets at the tertiary air level of a furnace (above the liquor sprayers) but it appears such interlacing was done without full appreciation as to the effects of interlacing. No interlacing at the primary and secon-dary levels of the boiler is disclosed.

Fridley and Barsin [Fridley, M.W. and Barsln, J.A., "Upgrading the Combustion System of a 1956 Vintage Recovery Steam Generator", Tappi Journal, March, 1988, page 63 and Fridley, M.W. and Barsin, J.A., "Upgrading a 1956 Vintage Recovery Steam Generator-II", Technical Section~ Canadian Pulp and Paper Industr'y, 1988 Annual Meetin~, Montreal] described modifications to an older CE-type boiler in 1986, to implement fully interlaced, i unopposed, air jets at the secondary level, below the liquor spray level. There was an improvement in boiler performance. They claimed a decrease in liquor spray carryover. Recent B & W designs of recovery boiler air systems also incorporate this full interlacing of air jets at the secondary level. None of these designs extend interlacing to the primary level.

SUMMARY OF THE INVENTION
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The invention pertains to a method of intro-ducing air at a given elevation into a furnace having .l four walls comprising: (a) introducing air through at i 30 least one opening located on a first wall of the inter-ior of the furnace; and (b) introducing air through at least one second opening located on a second wall of the ~! interior of the furnace opposed to the first wall.

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In the method, the air may be introduced into the furnace such that it has a horizontal or downward jet stream. The air may be introduced into the furnace through openings in the first and second opposing walls S at approximately the same air flow rate, and air may be introduced into the furnace ~hrough openings in the ~ third and fourth opposing walls of the furnace at a flow ; ~ate lower than the flow rate of the air through the ~; first and second walls.
,i~ 10 ~, In the method, the air may be introduced into ;~ the furnace at one elevation through the first and : second opposing walls at approximately the same air flow j rate, and air may be introduced into the furnace through i15 the third and fourth opposing walls of the furnace at a flow rate lower than the flow rate of air through the 3, - . first and second walls. Air may be introduced into the -i-`` furnace at a second elevation through the first and second opposing walls at approximately the same air flow rate, and air may be introduced into the furnace through the third and fourth opposing walls of the furnace at a flow rate lower than the flow rate of air through the ~ first and second walls. The boiler can be a kraft ;~ eecovery boiler.
~ 25 `~ The invention also pertains to a method of introducing air into a boiler furnace comprising: (a) , introducing air into the furnace by means of a first set of small and large jets originating from one wall of the interior of the furnace; and (b~ introducing air into the furnace by means of a second set of small and large jets originating from a wall of the interior of the fur-`~ nace opposite the first wall.

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-, , , - , , ` --`' 132~3q The positions of the first set of jets may be ! arranged so that a small jet in the first wall opposes a large jet in the opposite wall. ~he first set of small and large jets may alternate with one another. The 5 second set of small and large jets may alternate with one another.

In the method, a third and fourth set of alternating small and large jets may be located at an 10 elevation in the boiler higher than the first and second i set of jets. The first and second set of jets may orig-`~ inate from two opposing walls of the boiler furnace and a third and fourth set of jets may originate from two J opposing walls of the boiler furnace other than thesll 15 walls on which the first and second set of jets origi-~`~ nate.

.~.J In the method, the first set of jets may be pointed downwardly, horizontally, or slightly upwardly, 20 and the second set of jets may be pointed downwardly, horizontally, or slightly upwardly, into the interior of .3 the furnace. The small and large jets may originate from corresponding small and large ports located in the furnace wall. Alternatively, the small jets may origin-25 ate rom a first group of small ports located in the ` furnace wall and the large jets may originate from a second group of large ports of similar number to the first group located in the furnace wall. Alternatively, the ports may be of similar size and the large jets may 30 originate from a larger group of ports than do the small ^ jets.
!i In the method, the ports forming the jets may be similar in sixe and the large jets may be created by -' 35 .`-' ~
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~`1 air pressure at a higher level compared with the air pressure used to create the smaller jets.

The jets can be foemed by a group of ports `~ 5 similar in size and number and the large jets can be ~, created by air pressure at a higher level compared with ' the air pressure used to create the smaller jets.
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The invention is also directed to a furnace ~2, 10 with four walls which utilizes injected air comprising:
(a) a furnace chamber; (b) at least one air injection opening located on a first wall of the interior of the furnace; and (c) at least one second air injection open-ing located on a second wall of the interior of the fur-nace opposed to the first wall. At least a third air injection opening can be located on a third wall and at least a fourth air injection opening can be located on a fourth wall of the furnace opposed to the third wall.

' 20 In the furnace, the air may be injected into ~' the interior of the furnace either horizontally or down-wardly. The air may be in~ected into the furnace ~12 ~ through the first and second openings at abou~ the same ;i~ flow rate, and air may be injected into the furnace ~i 25 through at least one air injection opening located on a third wall of the interior of the furnace, and at least one air injection opening located on a fourth wall of ~,3 the interior of the furnace at a flow rate lower than ~ the flow rate of the air through the first and second ;~j2 30 walls.
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In the furnace, air may be injected into the ~ furnace at one elevation through openings in the first jj and second opposing walls at about the same flow rate and at a rate~ higher than the said flow rate through ~:
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'~2, , . ~ -32~37 ( openings in the third and fourth opposing walls; and air can be injected into the furnace at a second elevation through openings in the first and second opposing walls at about the same flow rate and at a rate higher than 5 the said flow rate through openings in the third and fourth opposing walls.

The invention also relates to a boiler furnace i which utilizes injected air comprising: (a) a furnace -~ 10 chamber; (b~ a first set of small and large openings ;~ located on one wall of the interior of the furnace; and (c) a second set of small and large openings located on i the wall of the interior of the furnace opposite the ~ first wall, the positions of the second set of openings ,,?'~ 15 being opposed in relation to the first set of openings so that a small opening in the first wall opposes a ~ large opening in the opposite wall, and a large opening s in the first wall opposes a small opening in the opposite wall of the furnace.
` 20 i In the furnace, the first set of small and large openings can alternate with one another. The second set of small and large openings can also alter-nate with one another. The air may be injected into the 25 interior of the furnace either horizontally or down-~! wardly.

i~ In the furnace, more openings of similar size can oppose fewer openings of similar size~
~7i 30 In the furnace, a third and fourth set of alternating small and large openings can be located at ;~ an elevation in the interior of the furnace, higher than the first and second set of openings. The first and 35 second sets of openings can be on two opposing walls of the boiler furnace interior and the third and fourth set ;~ _ 9 _ .~ .
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of openings can be on two opposing walls of the boiler furnace interior other than the walls in which the first and second set of openings are located.

'J 5 The boiler can be a kraft recovery boiler or a ; wood-waste fired boiler.
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~ `~ DRAWINGS
il, ' 10 In the drawings which illustrate specific em-i~ bodiments of the invention but which should not be construed as restricting the spirit or scope of the invention in any way:
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lS Figure la illustrates a plan view of a conven-tional boiler furnace at the primary air level with jet interference arising from air injected below the liquor spray level from all four walls of the furnace, at a ~it given elevation.
Figure lb illustrates a side view of a conven-~ tional boiler furnace with jet stream trajectories, for -~ the air introduced at the same elevation as in Figure la, in this case with no secondary air, and tertiary air ~ 25 introduced tangentially above the liquor spray level.

;~ Figure 2a illustrates a plan view of a conven-~. tional boiler furnace with four-wall air introduc~ion, :-.~ . .
~, below the liquor spray level.
;i~ 30 i Figure 2b illustrates a side view of a conven-i tional boiler furnace with air introduction from four walls at both the primary and secondary levels, below the liquor spray level, creating a central updraft, and ..
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~324~37( with tertiary air introduced above the liquor spray level.

Figures 3a ~nd 3b summarize air velocity measurements at the liquor spray level in 1/12th scale ` physical flow model of a traditional Combustion Engin-; eering-type recovery boiler, having just one level of ~, ~air below the liquor spray level.

i 10 Figure 4 illustrates a plan view of a boiler furnace with air introduction from two opposite walls, using fully (equally) opposed jets.

Figure 5a illustrates a plan view of a boiler furnace with fully interlacing (unopposed) jet streams ~ originating from opposing walls.

t Figure sb illustrates a side view of a boiler furnace with jet stream pattern created by fully inter-laced (unopposed) jet streams.

; Figures 6a and 6b summarize air velocity measurements at the liquor spray level in the physical flow model, with an added second level of air below the '~ 25 liquor spray level, operated with jets originating from 1 ~ the front and rear walls in fully interlaced (unopposed) ¦ fashion.
Figure 7 illustrates a plan view of a boiler furnace with partial interlacing jet streams (unequally opposed jets) originating from opposing furnace walls.
., Figures 8a and 8b summarize air velocity measurements at the liquor spray level in the physical flow ~odel, with an added level of secondary air below "

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the liquor spray, operated with jets originating ~rom ~ the front and rear walls in a partially interlaced -~ fashion, using unequally opposed jets.
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Figure 9 illustrates two plan views of a . boiler furnace with partially interlaced jet streams at a lower air level originating from one pair of opposing ~walls and an adjacent upper air level originating from ~' the other pair of opposing walls.
,~,10 ~ Figure 10 illustrates a plan view of a boiler 1 furnace with partially interlacing jet streams, using a register effect, in which several adjacent small jets ~j combine to form a single larger jet.
;J 15 Figure 11 illustrates four plan section views of three elevations in a boiler furnace utilizing par-,~4 tially and totally interlacing jet streams.

DETAILED DESCRIPTION OF A SPECIFIC
EMBODIMENT OF THE INVENTION
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Figures la, lb, 2a and 2b depict the detri-mental recirculation and central core updraft circula-tion patterns that exist in conventional boilers.
Supporting air velocity data obtained in a 1/12th scale ~ physical flow model are shown in Figures 3a and 3b. For `~ these data in Figures 3a and 3b, the model was operated . with two air levels: primaey air, equivalent to about 75% of the total air flow, coming equally from all four walls; and 25~ of the total air introduced tangentially ~, above the liquor spray level. A simila~r velocity profile was measured at the liquor spray level in the actual recovery boiler itself during special cold flow i testing.

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The inventors have taken two approaches to reduce gas velocity extremes and thereby reduce gas en-trainment of liquor spray particles.
~, ' 5 First, the air i5 introduced into the furnace `/ through as much port area as practically possible. This minimizes the velocities in the jets themselves while ~maintaining adequate jet stream momentum for good penetration. In this disclosure, the terms jet and jet 1 lO stream are used interchangeably and refer to the stream $ of gas that is emitted from the furnace wall through a specific opening (a port) or group of openings. Low velocity is particularly important with the primary jet I streams, which may impinge almost immëd~ately on the char bed, before they have had a chance to lose velo-!, city. Low velocity is also important for secondary air to be introduced to the lower furnace, immediately above , the primary air.

Secondly, the air is introduced in such a manner as to create a gross gas flow pattern in the fur-. nace that avoids or minimizes the adverse central up-draft core and any recirculation pattern. In the ideal case, the upflowing gases should be evenly distributed across the entire furnace horizontal cross-sectional area and the recirculation of gases from an upper region of the furnace to the bottom should be eliminated. In other words, plug flow upwards is the ideal case.

3~ The inventors have invented several ways to minimize velocity extremes in the bulk upflow of gases , in the furnace.
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~l Fully Opposed Primary Jets, on Two Opposite Walls A first level of improvement toward the ideal sitùation, that relates to boilers with only one level of air in the lower furnace, below the liquor gun level, particularly existing boilers of this design, can be achieved by using air ports on two opposite furnace walls only, preferably the front and rear walls. A system along these lines is illustrated in Figure 4. This is referred to herein as Fully Opposed Primary Jets on Two Opposite Walls. In this way, air is not introduced at right angles from the other two walls, at a given furnace elevation, and does not interfere with these first jets. Typically, in this invention, primary air is introduced on the front and rear walls only, with no primary air being introduced from the side walls. While this arrangement still produces a central updraft core, and a recirculating gas pattern with downflow adjacent to the front and rear walls, the area of the central updraft core is enlarged to occupy about 1/3 of the cross-sectional area instead of the normal 1/9 common with conventional four-wall primary operation. This increase in the area of the updraft core reduces the upward gas velocities in the central area of the furnace because more area is available for gas updraft.
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In existing boilers having primary air ports on all four walls, the approach can be implemented simply by closing the dampers in the registers ahead `of the ports on two opposite walls, preferably on the side walls.
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I ~ The first approach can be implemented partially, by ,"J injecting a greater amount of the primary air through one set -. of two opposing walls, for example, the front and rear walls, i and injecting a lesser amount through the other set of ~ opposing walls, for example, the left and right side walls.
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-~ On a boiler with two levels of air in the lower furnace below the liquor spray, this first approach would be best implemented by restricting the secondary air in the same way as the primary air; for instance, if all of the primary air, or most of it, comes from the front and rear walls, then all the secondary air, or most of it, should come from the front and rear walls.
-.,i ~ Full Interlacing (Unopposed Jets) .'.': .
Some level of improvement can be obtained relative to conventional practice by utilizing a jet interlacing pattern. Such a pattern is depicted in Figures 5a and 5b. In this arrangement, the ports are located on two opposing walls of the furnace, but the ports on the two opposing walls are offset so that the opposing jet streams interlace fully ~; without direct oppositlon and do not interfere with each other ;~ head-on. Wilcoxson, U.S. Patent No. 2,416,462, discloses a concept involving interlacing at the tertiary air level of the furnace, above the liquor spray level. Wilcoxson did not optimize the pattern at the tertiary level and 3~
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~,.3 .: . , : .:-` -` 132~37 ( did not apply it to the primary and secondary levels of the furnace below the liquor ~pray. Fridley and Barsin, referred to earlier, disclose full interlacing at the tertiary level as well as the secondary level, below the liquor spray level, but not at the primary level.

To avoid implngement of high oxygen-content gases on the furnace walls, there should be a minimum distance between the closest air jets and furnace wall ~i 10 parallel with, and adjacent to the outermost jets at a given elevation, say between the the side wall and the nearest ports in the front and rear walls of the : furnace. The minimum distance from the side wall should be determined by the spread pattern of the jet stream, and the decay of the centreline oxygen concentration.
The size, velocity, and orientation of each jet should be such that impingement on the opposing wall by gas having a high oxygen concentration is avoided. Further-more, if large ports are used, each port should have a ~' 20 damper.
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Figures 6a and 6b summarize the air velocity profile measured in a 1/12 scale physical flow model at the liquor spray level with an added second level of air below the liquor spray level operating with unopposed secondary jets from the front and rear walls in a fully interlaced fashion. Comparison of Figures 3a and 3b with 6a and 6b indicates that the chimney flow pattern ; of the traditional approach was broken, but there is little improvement in the uniformity of the velocities ~` on the furnace horizontal cross-sectional area at the ;~ liquor spray level because, with the fully interlaced J~ arrangement, there were high upwards velocities beside the front and rear walls. It was determined that the ~ 35 unopposed jets were sweeping up the opposite walls. The 'A,~

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same general pattern results with unopposed fully inter-lacing jets originating from the two side walls only.
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i operation with fully interlaced jets has the disadvantage that the ports need to be properly designed and operated carefully to minimize the impact of having the jets sweeping up the opposite walls with high velo-~ities.
., - 10 Partial Interlacinq (unequally Opposed Jets) il The inventors believe that a key to improving .~ the manner and efficiency in which the combustion air is . injected into the furnace is to minimize interference ,j 15 between the jets, while avoiding high velocities adjacent to the furnace walls and avoiding consequent impingement of high oxygen-content gas on the furnace ;~ walls. The interference of the jet streams with the i~ liquor spray is also of some concern. However, local '3: 20 velocity extremes can be reduced by using low initial jet velocities by using air ports as large as possible.
By avoiding interference between the air jet streams "
themselves, detrimental entrainment of liquor spray particles is further reduced.
; 25 While full air jet stream interlacing, using unopposed jets, provides an improvement over completely opposed jets in reducing jet interference, it is clear that complete jet stream interlacing has the disadvan-; 30 tage that it reduces the number of sites for air inlet i ports on a given furnace wall at a given elevation.
Thus, to enable the required quantity of air to be injected into the furnace at a given air level, either larger ports, or higher air velocities from the ports are necessary. For the air introduced above the liquor ;~

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sprayers, where the quantity of introduced air is not large, reduction in the number of entry sites is not a problem and complete interlacing is acceptable at that level.
i 5 At air entry locations below the liquor gun level, however, the necessary large size of the ports "'and/or high port discharge velocities becomes a problem, especially since the streams from big ports tend to sweep up the opposlte walls of the furnace with high ' velocity. The inventors have overcome this problem by ; inventing a partial interlacing pattern, using unequally opposed jets, as illustrated in Figure 7. With this , pattern, a larger jet originating from one urnace wall ~' 15 is opposed in an alternating fashion by a smaller jet originating from the opposite furnace wall. This pattern allows more total port area at a given air level `' and inhibits the jet streams from large ports from q sweeping the opposite furnace wall. Where the stream 20 from the bigger jet meets the stream from the smaller jet, they rise forming a small updraft. However, each updraft is a localized updraft without a significant re-;~ circulation pattern, rather than a large detrimental central updraft with an inherent recirculation pattern ~:; 2S that is significant.
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A large jet, partially opposed by a smaller jet, can be created in several ways:
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30 1. Use of a larger port, opposite a smaller port, 't/ with the same air pressure behind each port.

2. Use of a group of adjacent larger portsf opposite a group of a similar number of adjacent smaller ports, with the same air pressure behind all ports.

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~ ~.32~37 ( 3. Use of a group of ports o~ the same size with the same air pressu~e behind the ports, the larger jet being formed with a group of a larger number of ports than the smaller jet. For example, there could be two 5 adjacent ports opposite a single port, or three adjacent ports opposite two adjacent ports, etc.

~4. ~se of two opposing ports of the same size, ; but creatlng a higher pressure behind one of the ports 10 to obtain more flow and hence a larger jet than from the ~ opposing port.

`` S. Use of two groups of opposing ports, with about the same number of ports in each group, and all . 15 the ports about the same size, but creating a higher pressure behind-one of the groups of ports to obtain 7 more flow and hence a larger jet than from the opposing group of ports.

Basically, a large jet partially opposed by a ~! small jet, can be created by either a greater total port area on one wall~ opposite a smaller total port area on the opposite wall, all ports having the same air '~ pressure behind them, or similar total port area on the opposing walls, with a higher pressure behind the ports .!, on the one wall compared to the opposing wall.

A physical flow model tl/12 scale) of a tradi-tional Combustion Engineering-type recovery boiler was constructed and operated to test the inventors' theories. The model was operated with both water and air as the working fluid. With water as the working fluid, polystyrene pellets were introduced into the jet streams to enable the jet stream patterns to be seen and ;~ 35 ., ~, .

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to provide qualitative impressions. With air as the working fluid, quantitative measurements were made.
~, Figures 8a and 8b summarize the air velocity 5 profile measured in the physical model at the liquor spray level with an added second level of the air below the liquor spray level, operating with unequally opposed ~secondary jets oelginating from the front and rear walls in a partially interlaced fashion. comparison of 10 Figures 8a and 8b with Figures 3a and 3b indicates that ~' the chimney flow pattern of the traditional approach was broken and there was a substantial improvement in the uniformity of the velocity profile with partial ~ interlacing. Except for one high reading near the right p lS side close to the front, the velocity profile with partial interlacing is almost flat. Comparison of Figures 8a and 8b with Figures 6a and 6b indicates that partial interlacing is superior to full interlacing in . ,~
~`j providing a uniform velocity profile at the liquor spray .;~?' 20 level.
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With the full interlacing jet pattern shown in '~ Figure 5 and the partial interlacing ~et pattern in Fig-ure 7, there is no disadvantageous main central updraft . 25 core. Likewise, there is no detrimental recirculating pattern, as is the case with the arrangements depicted in Figures 1 and 3. In particular, partial interlacing ~ reduces velocity extremes in the furnace horizontal `~, cross-section area in the lower furnace below the liquor 30 spray level, relative to the conventional arrangements , depicted in Figures 1 and 3, and relative to the full interlacing arrangement in FigUre S.
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It is evident that with the partial inter-35 lacing or total interlacing concept of the invention, s using only two opposite walls (rather than all four '`;1 ~ 20 -~, ,~
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i32~37 walls) the arnount of air that can be introduced into the furnace at a given air level is limited, particularly if -` the port discharge velocity is to be kept low. The inventors have determined that this potential handicap 5 can be overcome by utilizing several air levels, for example, two, three or four, below the liquor spray . level, and another air level above the liquor sprayers.'~ith these different air levels, it is preferable that the opposing furnace walls used for introduction of air 10 at each level are alternated as shown in Figure 9. As shown, the jets on one elevation are positioned, for ~ example, on the front and rear walls of the furnace j while the jets on the next adjacent elevation are positioned on the respective side walls of the furnace, 15 and so on, for as many levels as are used. Furthermore, interference between two air levels relatively close together vertically can be reduced by orienting the ; ports in the lower level, downwardly or horizontally, while having the upper level oriented horizontally or 3s 20 slightly upwards. The final ~et orientation areangement is selected to provide as equal gas temperatures as -~ possible across the horizontal cross-section of the ~ furnace of the boiler. This objective is aided by ~ placing the uppermost layer of ports above the liquor `~ 25 spray level, in the front and rear walls of the furnace,;`~ rather than in the side walls.
,~ .
: Fridley and Barsin, referred to earlier, dis-i ~ close alternating the opposing furnace walls used for 30 introducing secondary air and tertiary air, in a boiler ~,~? ' having three air levels~ two levels below the liquor ~ spray level and a third level above ~he liquor spray 3 level. At both the secondary and tertiary levels, they applied a fully interlaced pattern using unopposed air 3~ 35 ~ets, using the front wall and rear wall at the secon-' ? - 21 -..i:
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dary level, and the two side walls at the tertiary level. ~heir disclosuee is limited to fully interlaced unopposed jets.
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.
S With total interlacing air jets as shown in ~i Figure 5, or partial interlacing as shown in Figure 7, it is important that no air is introduced at right angles to the interlacing pattern at that elevation. If air is introduced from ports in a third wall, or a third and fourth wall at the same elevation, then there is a tendency to form an adverse central updraft core.
: i ~' ~he shape of the port is also an important 3 contributing factor to promoting efficiency. Rectan-~,1 15 gular ports are known to mix the air into the furnace surroundings more quickly than do circular or square ports. For large ports, such as at the primary and secondary levels below the liquor spray level, where there is a large amount of air to be introduced at the same air level, rectangular ports are preferred. How-ever, for the tertiary air level, where a large region of the furnace is to be covered by a small quantity of air coming from a few ports, circular or square ports are preferred. These carry the oxygen in the air jet a greater distance before mixing and combusting.
.~ , The jets should preferably be introduced at several elevations in the furnace, using one of the two following methods at a given elevation:
j 30 1. A relatively small number of large ports, located in two opposing furnace walls, preferably with the jets paetially interlacing (or, less preferably, ':
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completely interlacing as is the pattern of the air introduced above the liquor spray level).
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2. A large number of smaller ports, rectangular in shape, arranged in groups forming a register effect :, , ` so that the jets in one group merge together a short ~$ distance from the wall to form one larger jet, as shown ~ ~in Figure 10. These groups would be located on two X opposing furnace walls, with the large compound jets 10 completely or partially interlacing.

~, It is evident that the problem with gas velo-~ city extremes and detrimental central updraft in recov-,-:,J ery boilers as presently constructed, originates at the i~ 15 primary air level and becomes accentuated at each -. successive higher air entry level. To address these problems utilizing the design concepts of the invention, two basic approaches can be taken. One approach is to completely eliminate or minimize the source of the prob-~ 20 lem. This approach involves using the jet stream .. ~t patterns illustrated in Figures 5, 7, 9 and/or 10 at all iJ air levels, especially the primary level. This approach 1, is expensive, however, and is applicable mainly to the ~;~ constructlon of new boilers.
;~ 25 i A second, less costly, approach involves mini-mizing modifications at the primary air level. With this approach, the updraft is permitted to develop at the primary level but the updraft is then corrected or minimized at the secondary and tertiary air levels by ,h applying the design patterns shown in Figures 5~ 7, 9 `~ and/or 10. In a sense, this approach can be regarded as putting a blanket over the upflowing gases, and in so doing, evening out the gas flow to minimize the velocity extremes. The first approach is preferred if expense is ` 1 ., ~ - 23 -,~.

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not a problem, or circumstances permit, although some success can be achieved with the second approach. As a ` general rule, the first approach should produce 3~0re `~ satisfactory and more extensive results.
A number of considerations should be taken into account in applying the design concepts and ;'patterns of the partial interlacing (unequally opposed jets) invention to each elevation in the boiler.
``,~ 10 i~;i A: Primary Air Level (Immediately above the char bed): Ideally, the primary air level should be modified according to the partial interlacing concepts shown in Figures 7, 9 and 10. However, in existing boiler retrofit situations, it may be desirable to ; restrict the modifications and use as many of the exist-ing ports as possible to minimize capital costs and to minimize port discharge velocities. In such retrofit s tuations, the partial interlacing concept involving the register effect, illustrated in Figure 10, should be ~ particularly suitable. When attempting to use most of ;`j the existing ports in a retrofit situation, it may not be possible to inject the required amount of air into the boiler if only two opposing walls are used for ports. Where this is the case, and ports are required ~3 on all four walls, jet interference can be minimized by the elevation and orientation of the ports. For one set of opposing furnace walls (e.g., the front and rear walls), the jets should be pointed downwards; for the 1 3~ other set of opposing furnace walls (e.g., the two side walls), the jets should be raised in elevation somewhat ~; and/or pointed closer to horizontal.

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B~ SecondarY Air Level (Approximately one metre above the primarY air level~: The partial interlacing arrangement shown in Figures 7, 9 and 10 is particularly useful for the secondary air level. This arrangement can be used in both new and retrofit situations.
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s~ C. Liquor Spray Level (Above the primary and secon-dary air levels): Air that infiltrates into the ports for the liquor gun nozzles enters the boiler with low velocity because of the low difference in pressure , between the outside and the inside of the furnace. The streams from these guns therefore have little momentum `~ and are readily deflected upwards. Because of this fact, the size of the liquor gun ports should be mini-~' 15 mized. A removable device can be used to blank off the open area around the gun.

, . . ~
D. Tertiary Air Level (Above the liquor quns): In conventional boilers with two full levels of air entry below the liquor spray level and one level of air above -1 the liquor spray level, five to twenty percent of the `~i total combustion air is introduced into the furnace at the tertiary level, some distance above the liquor guns.
~ The total combustion air quantity that is introduced `J 25 into the boiler is, however, only 105 to 110 percent of the stoichiometric air quantity. Therefore, the combus-.~
tion cannot be completed until the tertiary air is added. The basic thrust of the proposed system of the invention is contrary, namely to complete the combustion ~ 30 at as low an elevation in the furnace as possible. In 31 boiler operation, there is some volatilization of r~l hydrogen 5ulphide and organic combustibles, such as terpenes, from the liquor spray while the liquor spray travels across and down into the fuenace. For efficient ~ 35 .~, ~t :j ,~, ;` .
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/ ~ ~32~37 operation, these combustibles must be burned. Also, furnace gases coming from below the liquor gun level contain some combustibles such as CO and H2S. There can also be some oxygen in the furnace gases coming from below the liquor gun level because mixing may not be ideal at lower elevations in the furnace. If all of the combustion air ultimately required in the efficient ~peration of the boiler has been added below the liquor guns, then additional mixing, rather than more air, is . ~
all that is required at the tertiary level. Jets are .~ effective as mixing devices, so the requisite additional mixing can be provided by the introduction of any suit-able fluid such as air, steam or clean flue gas (for example, from the outlet of the precipitator of the ¦ 15 system) through suitably deslgned ports at the tertiary ! level. Where energ~ efficiency is important, re-cycled ' -- flue gas is the best option. Where either increased capacity or decreased odorous emissions are the most ~i~ im~portant, unheated ambient air is the best option. The '~! ...... 20 design concepts illustrated in Figure 5, depicting I complete interlacing with unopposed jets, can be used at the tertiary level. The mixing and penetration of these ;~ jets can be improved by angling them downwardly (e.g.
30) into the upflowing gases. Also, pointing the jets :; 25 downwardly delivers the air to a lower effective 1 elevation in the furnace, thereby helping to complete the combustion at as low an elevation in the furnace as possible. However, when directing the tertiary jets , downwards, care must be taken that they do not interfere i;` 30 with the liquor spray.
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`~ PROTOTYPE DESIGN

'l Figure 11 illustrates, in composite, three elevations in an actual boiler employing the patterns ~ .
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and design concepts discussed above in relation to Fig-ures 7, 9 and 10. Jet locations and relative air jet stream flows are depicted by means of pointed block arrows at the primary and secondary levels and pointed arrows at the tertiary level. For clarity, the primary level is broken into two depictions.
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As will be apparent to those skilled in the art, in the light of the foregoing dlsclosure, many alterations and modifications are possible in the prac-~ .~
tice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the inven-tion is to be construed in accordance with the substance defined by the following claims.
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Claims

WHAT IS CLAIMED IS:

1. A method of introducing primary air at the lowest airflow elevation into a boiler furnace comprising:
(a) introducing air into the furnace at the lowest air flow elevation by means of a first set of large jets originating from a first wall of the interior of the furnace;
(b) introducing air into the furnace by means of a second set of large jets originating from a second wall of the interior of the furnace opposite the first wall, at substantially the same elevation as the first set of large jets;
(c) introducing air into the furnace by means of a third set of small jets originating from a third wall of the interior of the furnace between the first wall and the second wall, at substantially the same elevation as the first and second sets of large jets; and (d) introducing air into the furnace by means of a fourth set of small jets originating from a fourth wall of the interior of the furnace between the first wall and the second wall, opposite the third wall, at substantially the same elevation as the first, second and third sets of jets.

2. A method according to claim 1 wherein air is introduced into the furnace using large jets originating from the first and second opposing walls with approxi-mately the same air flow rate from each wall, and air is introduced into the furnace using small jets originating from the third and fourth opposing walls of the furnace with flow rates from the third and fourth walls lower than the flow rate of air in the jets originating from the first and second walls.

- Page 1 of Claims -3. A method according to claim 1 wherein air is introduced into the furnace using large jets originating from the first and second walls and small jets originating from the third and fourth opposing walls of the furnace at substantially the same elevation as the first and second set of jets, and the air that is introduced to the furnace at said elevation is distributed so that a large portion of the air is distributed in substantially equal portions through the first and second walls, and a small portion of air is distributed in substantially equal portions through the third and fourth walls.

4. A method according to claim 2 wherein:
(a) secondary air is introduced using another first set of jets located at a second elevation higher than the lowest elevation on said first wall of the interior of the boiler furnace;

(b) secondary air is introduced using another second set of jets located on said second wall of the interior of the boiler furnace opposed to said first wall at substantially said second elevation higher than the lowest elevation; and (c) the remaining walls having no secondary air being introduced substantially at said second elevation higher than the lowest elevation.

5. A method according to claim 4 wherein the flow of secondary air is distributed approximately equally between the two opposed walls.

6. A method according to claim 3 wherein:
(a) secondary air is introduced using another first set of jets located at a second elevation higher than the lowest elevation on said first wall of the interior of the boiler furnace;
(b) secondary air is introduced using another second set of jets located on said second wall of the - Page 2 of Claims -interior of the boiler furnace opposed to said first wall at substantially said second elevation higher than the lowest elevation; and (c) the remaining walls having no secondary air being introduced substantially at said second elevation higher than the lowest elevation.

7. A method according to claim 6 wherein the flow of secondary air is distributed approximately equally between the two opposed walls.

8. A method according to claim 1, 2, or 3 wherein:
(a) secondary air is introduced using another first set of jets located at a second elevation higher than the lowest elevation on said first wall of the interior of the furnace;

(b) secondary air is introduced using another second set of jets located on said second wall of the interior of the boiler furnace opposed to said first wall at substantially said second elevation higher than the lowest elevation with approxi-mately the same flow rate of secondary air from the first and second walls; and (c) secondary air is introduced substantially at said second elevation higher than the lowest elevation using sets of jets located on said third and fourth walls of the interior of the furnace, between the first and second walls, the flow of secondary air through the third and fourth walls being less than the flow of secondary air through the first and second walls.

9. A method according to claim 1, 2, or 3 wherein the large and small jets originate from corresponding single large and small ports located in the respective furnace walls.

- Page 3 of Claims -10. A method according to claim 1, 2, or 3 wherein each large jet is formed by a combination of jets originat-ing from a first group of closely spaced large ports located in the respective furnace wall and each small jet is formed by a combination of jets originating from a second group of closely spaced small ports of similar number to the first group located in the respective furnace wall.

11. A method according to claim 1, 2 or 3 wherein each large jet is formed by a combination of jets originat-ing from a first group of closely spaced large ports located in the respective furnace wall and each small jet is formed by a combination of jets originating from a second group of closely spaced small ports of a different number than the first group located in the respective furnace wall.

12. A method according to claim 1, 2, or 3 wherein the large and small jets originate from ports that are of similar size and each large jet is formed by a combination of jets originating from a larger group of closely spaced ports than each of the small jets.

13. A method according to claim 1, 2, or 3 wherein the large and small jets originate from ports that are of similar size and each large jet is formed by a combination of jets originating from a pair of closely spaced ports and each small jet originates from a single port.

14. A method according to claim 1, 2, or 3 wherein the large and small jets originate from single ports of similar size and the large jets are created by air pressure at a higher level behind the respective ports compared with the air pressure behind the respective ports used to create the small jets.

- Page 4 of Claims -15. A method according to claim 1, 2, or 3 wherein each jet is formed by a combination of jets originating from a group of closely spaced ports similar in size and number and the large jets are created by air pressure at a higher level behind the ports compared with the air pres-sure behind the ports used to create the small jets.

16. A method according to claim 10, 11, 12, or 15 wherein each group of ports is a cluster of closely spaced ports with some of the ports in each cluster being at one elevation and the remaining ports being at one or more different elevations.

17. A boiler furnace which utilizes injected air comprising:
(a) a furnace chamber having four walls;

(b) a first set of large ports located at the lowest elevation on a first wall of the interior of the furnace;
(c) a second set of large ports located at the lowest elevation on a second wall of the interior of the furnace opposite the first wall;
(d) a third set of small ports located at the lowest elevation on a third wall of the interior of the furnace, between the first and second walls; and (e) a fourth set of small ports located at the lowest elevation on a fourth wall of the interior of the furnace opposite to the third wall.

18. A boiler furnace which utilizes injected air comprising:
(a) a furnace chamber having four walls;
(b) a first set of large ports located at the lowest elevation on a first wall of the interior of the furnace;
(c) a second set of large ports of similar size to the first set, located at the lowest elevation on - Page 5 of Claims -a second wall of the interior of the furnace opposite the first wall;
(d) a third set of small ports located at the lowest elevation on a third wall of the interior of the furnace, between the first and second walls; and (e) a fourth set of small ports of similar size to the third set located at the lowest elevation on a fourth wall of the interior of the furnace opposite to the third wall.

19. A boiler furnace which utilizes injected air comprising:
(a) a furnace chamber having four walls;
(b) a first set of ports located at the lowest elevation on a first wall of the interior of the furnace;
(c) a second set of ports of similar size to the first set, located at the lowest elevation on a second wall of the interior of the furnace opposite the first wall;
(d) a third set of ports of similar size as the ports in the first and second walls located at the lowest elevation on a third wall of the interior of the furnace, between the first and second walls;
(e) a fourth set of ports of similar size as the ports in the first and second walls located at the lowest elevation on a fourth wall of the interior of the furnace opposite to the third wall; and (f) dampers are associated with the ports on all four walls, for restricting the flow of air in the ports, said dampers being operated such that the flow of air through the third and fourth sets of ports is less than the flow of air through the first and second sets of ports.

- Page 6 of Claims -20. A boiler furnace which utilizes injected air comprising:
(a) a furnace chamber having four walls;
(b) a first set of ports located at the lowest elevation on a first wall of the interior of the furnace;
(c) a second set of ports of similar size to the first set, located at the lowest elevation on a second wall of the interior of the furnace opposite the first wall;
(d) a third set of ports of similar size as the ports in the first and second walls located at the lowest elevation on a third wall of the interior of the furnace, between the first and second walls;
(e) a fourth set of ports of similar size as the ports in the first and second walls located at the lowest elevation on a fourth wall of the interior of the furnace opposite to the third wall; and (f) dampers are associated with the ports on all four walls, for restricting the flow of air in the ports, said dampers being operated such that the flow of air through the third set of ports is somewhat less than the flow of air through the first and second sets of ports and the flow of air through the fourth set of ports is substan-tially less than the flow of air through the first and second sets of ports.
21. A boiler furnace which utilizes injected air comprising:
(a) a furnace chamber having four walls;
(b) a first set of ports located at the lowest elevation on a first wall of the interior of the furnace;
(c) a second set of ports of similar size to the first set, located at the lowest elevation on a - Page 7 of Claims -second wall of the interior of the furnace opposite the first wall;
(d) a third set of ports of similar size as the ports in the first and second walls is located at the lowest elevation on a third wall of the interior of the furnace, between the first and second walls;
(e) a fourth set of ports of similar size as the ports in the first and second walls is located at the lowest elevation on a fourth wall of the interior of the furnace opposite to the third wall; and (f) dampers are associated with the ports on all four walls, for restricting the flow of air in the ports, said dampers in the third and fourth walls being operated such that the flow of air through the third and fourth set of ports is substan-tially less than the flow of air through the first and second sets of ports.

22. A method according to claim 21 wherein the dampers associated with the ports on the third and fourth walls are closed, but leak sufficient air to keep the char bed away from the third and fourth walls and to keep the ports on the third and fourth walls relatively free from smelt deposits.

23. A boiler furnace according to claim 17, 18, 19, 20, 21, or 22 wherein:
(g) an additional first set of ports is located on said first wall of the interior of the furnace at an elevation above the lowest elevation;
(h) an additional second set of ports is located on said second wall of the interior of the furnace at an elevation above the lowest elevation and at substantially the same elevation as said addi-tional first set of ports; and - Page 8 of Claims -(i) the third and fourth walls having no ports located at substantially the elevation where said additional first set of ports and said additional second set of ports are located.

24. Boiler furnace according to claim 17, 18, 19, 20, 21, or 22 wherein:
(g) sets of ports are located on all four walls of the interior of the furnace at an elevation above the lowest elevation; and (h) dampers are associated with the ports on all four walls substantially at an elevation above the lowest elevation for restricting the flow of air in the ports at said elevation above the lowest elevation, said devices being operated such that the flow of air through the third and fourth sets of ports is less than the flow of air through the first and second sets of ports.
25. Boiler furnace according to claim 17, 18, 19, 20, or 21 wherein:
(g) sets of ports are located on all four walls of the interior of the furnace at an elevation above the lowest elevation; and (h) dampers are associated with the ports on all four walls substantially at an elevation above said lowest elevation, for restricting the flow of air in the ports at said elevation above the lowest elevation, said devices being operated such that the flow of air through the third and fourth sets of ports is considerably less than the flow of air through the first and second sets of ports.

- Page 9 of Claims -